How to replace timing chain on Vauxhall/Opel Astra J 1.3 CDTI ecoFlex

Special tools

• Camshaft locking tool x 2 – No.EN-46781.
• Camshaft sprocket holding tool – No.KM-6347.
• Camshaft sprocket holding tool handle – No.KM-956-1.
• Crankshaft pulley hub holding tool – No.KM-662-C.
• Crankshaft timing pin – No.EN-46785.
• Timing chain tensioner locking pin – No.KM-955-1.

General precautions

• Disconnect battery earth lead.
• Remove glow plugs to ease turning engine.
• Turn engine in normal direction of rotation (unless otherwise stated).
• Observe tightening torques.
• If fitted: Mark position of crankshaft position (CKP) sensor before removal.
• Do NOT turn crankshaft via camshaft or other sprockets.
• Do NOT turn crankshaft or camshaft with timing chain removed.

Valve timing procedures

• Removal/installation of timing chain requires:
  • Sump removal.
• Remove blanking plugs from camshaft housing [1] .
• Install camshaft locking tools [2] .
• Flat sections on camshaft locking tool must be in horizontal position [3] .
• Turn crankshaft in direction of rotation until both camshaft locking tools engage.
• Install crankshaft timing pin in bell housing hole:
  • 5 speed transmission [4] .
  • 6 speed transmission [5] .
• Compress timing chain tensioner and lock with timing chain tensioner locking pin [6] .
• Remove timing chain tensioner, tensioner rail and chain guide.
• Remove timing chain, crankshaft sprocket and camshaft sprocket as an assembly.
• Install timing chain, crankshaft sprocket and camshaft sprocket as an assembly.
• Tighten camshaft sprocket bolt to 150 Nm.
• Install timing chain tensioner, tensioner rail and chain guide.
• Remove timing chain tensioner locking pin [6] .

NOTE: Crankshaft damper hub bolt has LH thread. When replacing camshaft sprocket or crankshaft sprocket ensure writing on the sprocket faces outwards.

• Remove camshaft gears as follows:
  • Ensure camshaft locking tools correctly fitted [2] .
  • Remove camshaft housing.
  • Slacken bolt of each camshaft gear [7] .
  • Remove camshaft locking tools [2] .
  • Remove camshafts and camshaft gears.
• Install camshaft gears as follows:
  • Install camshafts and camshaft gears. Finger tighten bolts.
  • Install camshaft locking tools [2] .
  • Flat sections on camshaft locking tool must be in horizontal position [3] .
  • Tighten bolt of each camshaft gear to 150 Nm [7] .
  • Install camshaft housing.